U.S. patent number 4,884,309 [Application Number 07/256,721] was granted by the patent office on 1989-12-05 for method and apparatus for making shoe lasts and/or shoe components.
Invention is credited to Aharon Shafir.
United States Patent |
4,884,309 |
Shafir |
December 5, 1989 |
**Please see images for:
( Certificate of Correction ) ** |
Method and apparatus for making shoe lasts and/or shoe
components
Abstract
A method and apparatus for making shoe lasts, involves
digitizing on the fly a large number of sample points on the outer
surface of a model last representing a particular shoe style to
produce a model last digital file representing the
three-dimensional surface contour of the respective model last;
grading the model last digital file to produce one or more graded
last digital files each representing a different last size of the
respective soe style; and utilizing each of the graded last digital
files to produce a graded shoe last of the respective shoe style.
The invention may also be utilized for making graded components of
shoes, and for modifying shoe styles or creating new shoe styles by
CAD/CAM techniques.
Inventors: |
Shafir; Aharon (Tel Aviv,
IL) |
Family
ID: |
26806837 |
Appl.
No.: |
07/256,721 |
Filed: |
October 12, 1988 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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109297 |
Oct 15, 1987 |
4817222 |
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Current U.S.
Class: |
12/1R;
12/146L |
Current CPC
Class: |
A43D
1/04 (20130101); A43D 119/00 (20130101); G05B
19/4207 (20130101); G05B 2219/35038 (20130101); G05B
2219/45243 (20130101) |
Current International
Class: |
A43D
119/00 (20060101); A43D 1/04 (20060101); A43D
1/00 (20060101); G05B 19/42 (20060101); A43D
001/04 (); A43D 001/00 () |
Field of
Search: |
;12/146L,7R,1R
;364/474.34 ;128/661.01 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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2308062 |
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Aug 1973 |
|
DE |
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2721753 |
|
Nov 1977 |
|
DE |
|
1414298 |
|
Nov 1975 |
|
GB |
|
Primary Examiner: Meyers; Steven N.
Attorney, Agent or Firm: Brown; Donald Barish; Benjamin
J.
Parent Case Text
This is a divisional of co-pending Ser. No. 109,297, filed on Oct.
15, 1987, now U.S. Pat. No. 4,817,222.
Claims
What is claimed is:
1. Digitizing apparatus, comprising:
a rotary motor for rotating a last about its longitudinal axis,
constituting a first axis;
a first encoder producing an electrical output representing the
instantaneous angular position of the model last about said first
axis;
a tracer probe;
a spring urging said tracer probe along a second axis.
Perpendicular to said first axis, in contact with the outer surface
of the model last as the model last is rotated by said motor about
said first axis;
a second encoder producing an electrical output representing the
instantaneous linear position of said tracer probe along said first
axis;
linear drive means for driving said tracer probe along a third axis
parallel to said first axis;
and a third encoder producing an electrical output representing the
instantaneous linear position of the tracer probe along said third
axis.
2. The apparatus according to claim 1, wherein said tracer probe is
a wheel rollable along the outer surface of the last while
spring-urged into contact therewith.
3. The apparatus according to claim 2, wherein said last includes
an electrically-conductive feather line, and said tracer wheel is
of electrically conductive material so as to sense said
electrically conductive feather line.
4. The apparatus according to claim 1, further including an optical
sensor for sensing optically-sensible style-lines on said last.
Description
BACKGROUND OF THE INVENTION
The present invention relates to a method and to an apparatus for
making shoe lasts and/or components for shoes.
A shoe last is a block or form shaped like a human foot used in
manufacturing shoes and also in repairing shoes. In the manufacture
of shoes, a model last is produced for each particular shoe last
style, and then a plurality of graded lasts are produced according
to the different lengths and widths to be made available for the
respective shoe style.
The grading procedure is usually not a straightforward one wherein
all dimensions are proportionately increased with the increase in
size; rather, to avoid distortions, and also to minimize the
initial tooling costs (e.g., moulds) required to manufacture the
shoe components, many dimensions are not increased, or are
disproportionately increased, for a plurality of grades. For
example, "bottom-holding", "heel-height holding", "toe-spring
holding", and "toe-thickness holding" techniques are frequently
used in order to maintain certain dimensions for a plurality of
sizes, or to change the dimensions in a non-linear manner with
respect to the different sizes.
An important factor of the respective style influencing the grading
procedure is the feather line of the model last, namely the
juncture line of the last bottom with the last sides. The feather
line determines the outer configuration of the last bottom and is
frequently involved in these "holding" techniques.
Generally speaking, producing graded lasts from a model last not
only requires a high degree of expertise and experience, but also
is very expensive and time- consuming. According to present
techniques, a model last for each style is first produced by an
artisan model-maker, and then the graded lasts, corresponding to
the different sizes of the same basic style, are usually prepared
by a pantograph machine, in which the different sizes are produced
by adjusting the arms of the pantograph. However, this method
produces considerable distortions which are cumulative; that is, a
distortion from one size to the next may not be too significant,
but they become very significant when they are magnified by
differences in three or four sizes. These distortions therefore
require considerable "retouching" by the last maker; moreover, they
limit the variations possible as a practical matter in the
different grades.
The components (e.g., the flat leather, plastic, fabric blanks for
making the sides, soles, heels, etc.) used in manufacturing the
shoe are uusually indicated by style-lines marked on the model
last. These style-lines also indicate the stitching lines of the
various components used in the manufacture of the shoes, and
thereby the configurations of such components. Techniques are known
for converting the three-dimensional configuration of a shoe
component, as determined by three or more style-lines on the shoe
last, to a two-dimensional configuration for manufacturing the
respective components. However, determining the three-dimensional
configuration of the components in all the grades (sizes) of the
respective shoe style is also very time-consuming and requires a
high degree of expertise and experience.
BRIEF SUMMARY OF THE INVENTION
An object of the present invention is to provide a novel method and
apparatus for making shoe lasts having advantages in the above
respects. Another object of the invention is to provide a novel
method and apparatus which may be also used for making the graded
components of the shoes.
According to the present invention, there is provided a method of
making shoe lasts, comprising: digitizing a large number of sample
points on the outer surface of a model last representing a
particular shoe style to produce a model last digital file
representing the three-dimensional surface contour of the
respective model last; grading the model last digital file to
produce graded last digital files representing different last sizes
of the respective shoe style; and utilizing the graded last digital
files to produce graded shoe lasts of the respective shoe
style.
According to an important feature in the preferred embodiments of
the invention described below, the method includes the further
steps of digitizing a large number of sample points on the feather
line of the model last to produce a feather line digital file
representing the feather line of the respective model last; and
utilizing the feather line digital file, together with the model
last digital file, for producing the plurality of graded last
digital files of the respective shoe style.
The described preferred embodiments also include the further step
of digitizing a large number of sample points on preselected
style-lines of the model last to produce a style-line digital file
for the respective shoe style. Such a style-line digital file may
be used, together with the model last digital file, for producing a
plurality of graded component digital files representing different
sizes and configurations of the components e.g., the flat leather
blanks, used in manufacturing the respective shoe style.
The invention also provides apparatus for use in making shoe lasts,
comprising: rotary drive means for rotating a model last
representing a particular shoe style; digitizing means for
digitizing a large number of sample points on the outer surface of
the model last to produce a model last digital file representing
the three-dimensional surface contour of the respective model last;
and grading means for producing from the model last digital file a
plurality of graded last digital files representing different
lengths and widths of lasts of the respective shoe style.
In one preferred embodiment described below, the digitizing means
comprises a tracer probe in the form of a rotary wheel; rotary
drive means for rotating the model last about its longitudinal
axis, constituting a first axis; a first encoder producing an
electrical output representing the instantaneous angular position
(e.g., ".theta.") of the model last about the first axis; a spring
urging the tracer probe along a second axis in contact with the
outer surface of the model last as the model last is rotated by the
rotary drive means about the first axis; a second encoder producing
an electrical output representing the instantaneous position (e.g.,
"X") of the tracer probe along the second axis; linear drive means
for driving the tracer probe along a third axis parallel to the
first axis; and a third encoder producing an electrical output
representing the instantaneous linear position (e.g., "Z") of the
tracer probe along the third axis.
In this described embodiment, the digitizing operation measures the
instantaneous position (X, .theta., Z) of the tracer probe at each
sample point to represent the "tool" path points (i. e., the center
point of the tracer wheel) on the three-dimensional surface contour
of the respective model last; and the grading operation converts
the tool path points to "part" points on the surface of the model
last, grades the part points to represent different lengths and
widths of lasts of the respective shoe style, and then reconverts
the graded part points to tool path points in the graded digital
files.
In a second described embodiment, the digitizing means comprises a
optical device directing an optical beam, such as a laser beam,
against the outer surface of the model last as the model last is
rotated about its longitudinal axis, and as the optical beam is
advanced parallel to the longitudinal axis of the model last. In
this described embodiment, the digitizing operation directly
measures the part points on the surface of the model last; and the
grading operation grades the part points to represent different
lengths and widths of lasts of the respective shoe style, and then
converts the graded part points to tool path points in the graded
digital files.
As will be described more particularly below, the novel method and
apparatus may be used for making graded shoe lasts, and also graded
components of shoes, in a quick and efficient manner as compared to
the present techniques. Moreover, the method and apparatus of the
present invention permits various "holding" techniques to be
conveniently applied in order to hold a particular dimension of the
shoe last for more than one grade, or to provide a disproportionate
change in one or more dimensions with respect to the other
dimensions among different grades. Such techniques may be used to
avoid distortions in the graded shoes, and also to minimize the
initial tooling required to make the shoe components.
The method and apparatus may be embodied in new equipment
specifically designed for making shoe lasts or components in
accordance with the invention, or may be added to existing
equipment, e.g., of the pantographic type, to retrofit such
equipment for making graded shoe lasts in accordance with the
present invention.
Further features and advantages of the invention will be apparent
from the description below.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is herein described, by way of example only, with
reference to the accompanying drawings, wherein:
FIG. 1 is a block diagram illustrating one form of apparatus
constructed in accordance with the present invention for making
shoe lasts and/or shoe components;
FIG. 2 illustrates a typical model last representing a particular
shoe style used for producing graded lasts for the different sizes
of the respective shoe style;
FIG. 3 illustrates the digitizing means included in the apparatus
of FIG. 1;
FIG. 4 is a three-dimensional view illustrating the three axes
defining the sample points on the outer surface of the model
last;
FIG. 5 is a block diagram illustrating the digitizer computer in
the system of FIG. 1;
FIG. 6 is a flow diagram illustrating the man-machine interface
(MMI) software in the digitizer computer of FIG. 1;
FIG. 7 is a flow diagram illustrating the operation of the
digitizer computer of FIG. 1;
FIG. 8 is a flow diagram illustrating the man-machine interface
(MMI) software in the grading computer of FIG. 1;
FIG. 9 is a flow diagram illustrating the operation of the grading
computer in the system of FIG. 1;
FIGS. 10a and 10b are diagrams helpful in explaining the manner of
determining the part points i.e., the points on the surface of the
model last, from the measured tool path points;
FIG. 11a illustrates a model last and one graded last produced
therefrom, including different part of such lasts, and also
illustrates the manner of modifying the change in one of the
dimensions (i.e., toe spring) in the produced graded last to avoid
distortions;
FIGS. 11b and 11c are diagrams illustrating, in full lines, lasts
which have been graded proportionately, and in broken lines the
modifications of the graded lasts in order to apply other "holding"
techniques for avoiding distortions for minimizing initial tooling
costs;
FIG. 12 is a flow diagram illustrating the application of a "bottom
holding" technique in producing a graded last;
FIG. 13 is a last diagram helpful in explaining the heel-height
holding technique;
FIG. 14 is a flow diagram explaining the heel-height holding
technique applied to the last illustrated in FIG. 13;
FIGS. 15a and 15b are diagrams helpful in explaining the manner of
modifying the digital data identifying each sample point on the
surface contour of the last according to the "holding" technique
applied to the last;
FIG. 16a illustrates a last having a number of style-lines marked
thereon to indicate the configurations of different components used
in manufacturing the shoe corresponding to the last;
FIG. 16b is a flow diagram illustrating the manner of using the
style-lines in FIG. 16a for producing the graded components used to
manufacture the shoes of the graded lasts;
FIG. 17 illustrates an optical digitizer, namely a laser system,
which may be used for the digitizer in the system of FIG. 1;
and
FIG. 18 is a flow diagram illustrating the operation of the grading
computer when using the laser digitizer of FIG. 17.
DESCRIPTION OF PREFERRED EMBODIMENTS
Overall System Illustrated in FIG. 1
FIG. 1 is a block diagram illustrating an overall system for making
shoe lasts in accordance with the present invention. The system
includes a digitizer, within the block generally designated 2,
which digitizes a large number of sample points on the outer
surface of a model last ML representing a particular shoe last
style. This digital information is outputted to a digital computer
4 which produces a model last digital file 5 representing the
three-dimensional surface contour of the respective model last.
FIG. 2 illustrates one form of model last ML representing a
particular shoe style. Among its other components, the illustrated
model last ML includes a last bottom LB, a last heel LH, and last
sides LS. The juncture line of the last sides LS with the last
bottom LB and last heel LH is called the feather line FL, and is an
important element in the shoe style of the respective last. As also
seen in FIG. 2, the last sides LS include a plurality of
style-lines SL, which are important elements not only in the
particular shoe style of the respective last, but also in the
configuration of the components, e.g., leather blanks, used in
making the shoe of the respective style.
Digitizer unit 2 illustrated in the system of FIG. 1 digitizes not
only the sample points on the outer surface of the model last ML to
produce the model last digital file 5, but also digitizes the
feather line FL of the model last, which information is outputted
to the digitizer computer 4 to produce a feather line digital file
6. Digitizer 2 also digitizes the style-lines SL of the model lasts
ML, which information is also outputted to the digitizer computer 4
to produce a style-line digital file 7. Since the feather line file
6 and the style-line file 7 are substantially smaller than the
model last file 5, files 6 and 7 may be integrated into a single
joint file, and thereafter processed as a single file with the
model last file 5. These files may be embodied in diskettes,
cassette tapes, or in any other suitable form.
As further shown in FIG. 1, the digitizer file 5, feather line file
6, and style-line file 7 ,are inputted into a grading computer 8
which produces a plurality of graded last digital files. These may
also be embodied in the form of diskettes or cassette tapes
suitable for use in a CNC (computerized numerical control) last
cutting machine, indicated at 10, which uses this information for
cutting the plurality of graded lasts for each shoe style
represented by the model last ML. The graded last files 9 may also
be used in an existing last-cutting machine (e.g., of the known
pantographic type) retrofitted, as indicated at 11, so as to
receive the graded last files 9 and to use this information for
cutting the graded lasts.
The grading computer 8 may also produce a plurality of graded
component files 12 for the components, e.g., leather blanks, used
for making the shoes in the various grades of the particular shoe
style of the model last ML. The graded component files 12, also in
the form of diskettes or cassette tapes for example, may be
inputted into existing component cutting machines, indicated at 13,
for cutting the graded components to be used for making the
shoes.
The digitizer computer 4 includes a keyboard KB.sub.1 and a display
DISP.sub.1 enabling operator control of the computer to produce the
three files, 5, 6 and 7, as will be described more particularly
below. Similarly, the grading computer 8 also includes a keyboard
KB.sub.2 and a display DISP.sub.2 enabling operator control of the
computer to produce the files 9 and 12, as will also be described
more particularly below.
The Digitozer Unit 2
FIG. 1 illustrates in block diagram form the electrical system
included in the digitizer unit 2; FIG. 3 illustrates the mechanical
construction of the digitizer unit 2; and FIG. 4 illustrates the
digital coordinates (X, .theta., Z) of each of the sample points on
the outer surface of the model last which are measured by the
digitizer unit 2 to produce the model last digital file 5 as well
as the feather line file 6 and style-line file 7.
As shown in FIG. 1, digitizer unit 2 includes a rotary motor
M.sub..theta. for rotating the model last ML about its longitudinal
axis, hereinafter referred to as the turning center line TCL, and
an encoder E.sub..theta. producing an electrical output
representing the instantaneous angular position (.theta.) of the
model last ML about line TCL. The digitizer unit further includes a
tracer probe TP urged by a spring 14 along a second axis (X-axis)
into contact with the outer surface of the model last ML as the
model last is rotated about its turning center line TCL, and an
encloder E.sub.X producing an electrical output representing the
instantaneous position of the tracer probe along the X-axis.
Digitizer unit 2 further includes a motor M.sub.Z for driving the
tracer probe TP along a third axis (the Z-axis), parallel to the
turning center line TCL of the model last ML, and an encoder
E.sub.Z producing an electrical output representing the
instantaneous linear position of the tracer probe TP along the
Z-axis.
As shown in FIGS. 4 and 4a, each point in space is defined, in each
plane, by polar coordinates, namely by the dimension "X", being the
instantaneous linear position of the center of the tracer probe TP
along the X-axis, and the angle .theta., being the instantaneous
angular position of the last about the turning center line TCL; and
each plane is defined by the instantaneous linear position of the
tracer probe TP along the Z-axis. The center points of the tracer
probe thus represent the "tool" path points (points "T" in FIG.
10a). Since the diameter of the tracer probe TP is known, the
position in space of the surface contact point on the outer contour
of the last (referred to as the "part" points in FIG. 10a) can be
easily determined.
Encoders E.sub.X, E.sub..theta. and E.sub.Z may be digital-type
encoders of known construction which output a series of digital
pulses representing their respective instantaneous values;
alternatively, the encoders could be of the analog type, in which
case the analog information outputted by them would be converted to
digital form by an analog-to-digital converter, as also known. As
described above, the digital information
from the encoders E.sub.X, E.sub..theta. and E.sub.Z is inputted
into the digitizer computer 4 for producing the respective
digitizer file 5, feather line file 6, and style-line file 7, under
the control of the operator via keyboard KB.sub.1 and display
DISP.sub.1.
The mechanical construction of the digitizer unit 2 is more
particularly illustrated in FIG. 3. The tracer probe TP is in the
form of a wheel which is urged by loading spring 14 (a second one,
not shown, being provided on the opposite side of the wheel) into
contact with the outer surface of the model last ML. The model last
is secured between a heel dog 16 and a tail stock 18, and is
rotated by electrical servomotor M.sub..theta. about the
longitudinal axis TCL. The tracer probe wheel TP, and its loading
spring(s) 14, are carried by a carriage 20 movable along a pair of
rails 22 parallel to the longitudinal axis TCL of the model last ML
by means of a ball screw 24 rotated by the servomotor M.sub.Z.
Thus, by operating motor M.sub..theta. to rotate the model last ML
about its longitudinal axis TCL and by operating motor M.sub.Z to
drive the tracer probe wheel TP along the Z-axis, parallel to the
longitudinal axis TCL of the model last, the tracer probe wheel TP
scans the complete outer surface of the model last.
During the scanning operation, the instantaneous position of the
tracer probe TP on the outer surface of the model last ML, as
measured by the respective encoders E.sub.X, E.sub..theta. and
E.sub.Z, is periodically recorded. This data thus identifies the
sample points on the outer surface of the model last representing
the particular shoe style of the last. A large number of sample
points, e.g., in the order of 15,000, is required for this purpose;
for example, 90 sample points may be taken for each plane or slice,
and 100-200 slices may be taken, depending on the model last.
However, since the sample points are taken "on the fly" during the
continuous rotation of the model last ML, the complete digitizing
procedure may be done in only a few minutes, whereas automatic
point-to-point sampling of the outer surface of the last would take
many hours.
During this digitizing procedure, rotary motor M.sub..theta., which
rotates last ML, is operated continuously. Servomotor M.sub.Z may
also be operated continuously to move the tracer probe wheel TP
along the Z-axis, in which case the scanning of the outer surface
of last ML by the tracer probe TP would be in a spiral manner.
Alternatively, servomotor M.sub.Z may be operated intermittently,
following each rotation of the model last ML by the servomotor
M.sub..theta., in which case the scanning of the outer surface of
the model last by the tracer probe TP would be in a stepped
manner.
Digitizer unit 2 illustrated in FIG. 3 further includes two limit
switches LS.sub.1, LS.sub.2, at the opposite ends of the model last
ML and engageable by elements carried by carriage 20. Switches
LS.sub.1, LS.sub.2 limit the linear movement of the carriage along
the Z-axis.
Carriage 20 further includes an optical sensor OS used for sensing
the style-lines SL (FIG. 2) of the model last ML. For this purpose,
the style-lines SL on the model last ML have a different optical
characteristic from the remainder of the model last ML; for
example, the model last could be of a light color, and the
style-lines SL could be of a dark color.
Optical sensor OS may also be used for sensing the feather line FL
of the model last ML. Preferably, however, the feather line FL is
sensed by the tracer probe TP. For this purpose, the model last ML
is of electrically insulating material except for the last bottom
LB (FIG. 2), which is of electrically conductive material. Thus,
the juncture line between the last bottom LB and the last sides LS,
constituting the feather line FL of the last, is detectable by the
electrically-conductive tracer probe TP.
The digitizer unit illustrated in FIG. 3 further includes a handle
26 carried by the tail stock 18 to enable manual attachment and
detachment of the model last ML.
The Digitizer Computer 4
Digitizer computer 4 in the system of FIG. 1 is more particularly
illustrated in FIG. 5; its main machine interface (MMI) software is
illustrated in the flow diagram of FIG. 6; and its overall
operation is illustrated in the flow diagram of FIG. 7.
With reference first to FIG. 5, it will be seen that the digitizer
computer 4 includes three axes controllers, namely AC.sub.X for the
X-axis, AC.sub..theta. for the angular position .theta. about the
turning center line TCL, and AC.sub.Z for the Z-axis. As one
example, each of the three illustrated controllers may be an
Intelligent Axis Card (IAC) in the Anomatic III CNC controller
produced by Anorad Corporation of Hauppauge, New York. Such
controllers are well-known and are commercially available.
Axis controller AC.sub..theta. controls rotary motor M.sub..theta.
via its motor drive unit MD.sub..theta. and receives the
instantaneous angular position of the tracer probe TP via encoder
E.sub..theta. ; and axis controller AC.sub.Z controls linear motor
M.sub.Z via its motor drive unit MD.sub.Z, and receives the
instantaneous linea position of the tracer probe TP along the
Z-axis via excoder E.sub.Z. Tracer probe TP is moved along the
X-axis by spring(s) 14, and axis controller AC.sub.X receives the
instantaneous linear position along the X-axis via encoder E.sub.X.
The two controllers AC.sub.Z and AC.sub..theta. also receive
information from the two limit switches LS.sub.1, LS.sub.2.
The information from the three controllers is transmitted to the
central processor unit CPU via busses 30 and 32. Central processor
unit CPU may be an 8088 processor, including an optional 8087
co-processor, and bus 30 may be an RS 422 bus, all as included in
the Anomatic III CNC controller.
The digitizer computer illustrated in FIG. 5 further includes a
servo co-processor 34, which periodically (e.g., every 4.degree. of
angular movement of the model last ML, to provide 90 sample points
for each plane or slice) collects data from the X-axis controller
AC.sub.X and the .theta.-axis controller AC.sub..theta., and places
this information in a buffer for transfer to the central processor
unit CPU when ready.
The central processor unit CPU also receives information from a
sensor unit 36, which senses the feather line FL and the
style-lines SL on the model last. As described above, the tracer
probe TP may be used for sensing the feather line FL if the last
bottom LB (FIG. 2) is of electrically-conductive material, and the
last side LS is of insulating material, in which case the tracer
probe TP would be of electrically-conductive material;
alternatively, the optical sensor OS in the digitizer unit
illustrated in FIG. 3 may be used not only for sensing the
optically-sensible style-lines SL, but also the feather line FL.
When sensor 36 senses a point on the feather FL or style-line SL,
it interrupts the information supplied to the central processor
unit CPU and stores the coordinate positions for ultimate transfer
to the respective feather line file 6 or style-line file 7.
The central processor unit CPU is controlled by a program recorded
in a hard disk 38 and inputted via input bus 40. The digitized data
from the central processor unit CPU is outputted via bus 40 and
recorded in diskettes 42 in a manner to be subsequently used in the
grading computer 8 (FIG. 1) for producing the graded files.
The digitizer computer 4 illustrated in FIG. 5 further includes a
graphic axis emulator 46, which continuously displays the X,
.theta., Z positions of the digitizer in real time. Computer 4
further includes a Real Time Graphic Integrator 48, and an I/O
master base board 49 which, controlled by the program inputted by
the hard disk 38, performs a number of functions, including
withdrawing the tracer probe TP, stopping the operation of the
machine under the control of the limit switches LS.sub.1, LS.sub.2,
and also giving an alarm should one of the limit switches LS.sub.1,
LS.sub.2 be actuated.
The central processor unit CPU is also connected by bus 40 to other
input/output devices, e.g., a printer 50 via bus 52, and also via
bus 54 to a serial communication link 56 for transmission to remote
locations. Line 56, for example, may transmit the digitized model
last data by telephone or wire to a last-manufacturing location
from the model-last digitizing location.
The operation of the central processor unit CPU can be controlled
by man-machine interface software via keyboard KB.sub.1 and display
DISP.sub.1. By means of this interface, the operator inputs via
keyboard KB.sub.1 special information to control the digitizing
operation, e.g., information identifying the name of the last file,
the total length of the last file, the pitch of the scanning
spiral, the number of points to pick up per turn, the starting
point of digitizing (starting from the heel), and the "heel back"
length (in case the pitch is to be reduced at the back of the
heel). The MMI software questions to the operator, and the
information inpulled by the operator in response thereto, can be
viewed via display DISP.sub.1.
FIG. 6 is a flow diagram illustrating the man-machine interface
software for the digitizing computer 4.
Thus, the operator, after pressing "on", enters the file name. For
example, the file name may contain eight alphanumeric characters
and three extension characters. The first five charcters designate
the style identification (e.g., A1532); the next three characters
designate the size (e.g., B-08); and the three extension characters
identify the type of data, e.g., "DGT" identifying a digitizer
file, "ANS" identifying a feather line or style-line file, and
"CNC" identifying a produced "CNC" file.
Following the entry of the file name, the operator enters the
number of points for each turn of the model last; for example, the
operator may enter 90 points for each turn.
The operator then enters the pitch length, namely the advance along
the Z-axis per rotation, and the Last Length, namely the total
length of the last.
The operator is then requested by the program to enter the
following further data:
(a) Starting back, namely how far back from the first sample point
of the last; if no value is entered by the operator, the program
automatically enters "10".
(b) Heel length, namely what length of heel for which to use the
finer (e.g., one-half) heel pitch; if no value is introduced by the
operator, the program automatically enters "20 mm".
(c) Digitation speed, namely the mm/second; if no answer is entered
by the operator, the program automatically enters "255 mm/sec".
(d) Active sensor, namely whether the optical sensor for sensing
the style-line and/or the feather line sensor for sensing the
feather line is to be active; if no answer is entered by the
operator, the program automatically enters "Yes", indicating that
both sensor are to be active.
After all the foregoing information is entered, the operator then
presses "Go".
Reference is now made to the flow diagram of FIG. 7 illustrating
the operation of the digitizer computer 4 in FIG. 1. The axes
controllers AC.sub.X, AC.sub..theta., AC.sub.Z, are strobed every
4.sup.0 (in this particular example),
and the positions of the rotary encoder E.sub..theta. and the
linear encoder E.sub.X are transferred via busses 30, 32 (FIG. 5)
to the CPU. This positional data is collected in the CPU and is
stored in its memory buffer in binary form. Thus, the memory buffer
in the CPU continuously stores the instantaneous angular position
(.theta.) of the model ML about the turning center line TCL of the
last as detected by the rotary encoder E.sub.O, and also the
instantaneous linear position (X) of the tracer probe TP along the
X-axis, as detected by the linear encoder E.sub.X.
The instantaneous positions of the tracer probe TP along the
Z-axis, as detected by the linear encoder E.sub.Z, is also read
into the CPU and stored in its buffer memory. As indicated earlier,
linear motor M.sub.Z which drives the tracer probe TP along the
Z-axis (along rails 22 in FIG. 3), may be operated either
continuously (wherein a spiral scan is produced by the tracer probe
about the model last ML), or intermittently (wherein a stepped scan
is produced).
The positional data stored in the memory buffer of the CPU includes
not only the spacial locations of the sample points on the outer
surface of the model last ML, but also the spacial locations of the
feather line FL (FIG. 2) and of the style-lines SL. As described
earlier, the feather line FL is detected by the tracer probe TP by
making the tracer probe and the last bottom LB of
electrically-conductive material, while the last sides LS are made
of electrically-insulating material; and the style-lines SL are
detected by the optical sensor OS (FIG. 3) carried by the carriage
20 which also carries the tracer probe TP.
For purposes of example, about 15,000 sample points on the outer
surface of the model last ML are recorded to define the outer
contour of the model last for the respective shoe style, and also
the featherline FL and style-lines SL of the respective model last.
In the described preferred embodiment, 90 sample points are
recorded for each plane or "slice" of the model last ML, and from
100 to 200 (e.g., 167) slices may be recorded, depending on the
length of the model last. Accordingly, the memory buffer in the CPU
has a capacity of 15,000 sample points.
At the end of each rotation of the model last, corresponding to one
increment of movement along the Z-axis, a check is made as to
whether the memory buffer is full. If the buffer is not full, a
check is made to determine whether the end of the last has been
scanned; if not, the rotary motor M.sub..THETA. is continued to
operate to rotate the model 1st another turn. If, however, it has
been determined that the end of the last has been scanned, the data
in the memory buffer is transferred to the hard disk (38, FIG. 5),
and the memory buffer is cleared. The data stored in the hard disk
may thereafter be transferred to the diskette 42 for further
processing in the grading computer 8 of FIG. 1.
As shown in FIG. 1 the digitizer computer 4 produces a model last
file 5 representing the sample points on the three-dimensional
surface contour of the respective model last; a feather line file 6
representing the sampled points on the feather line FL of the model
last; and a style-line file 7 representing the sampled points on
the style-lines SL of the model last. The model last file 5 is
recorded in one diskette, but since the feather line file 6 and
style-line file 7 are both relatively small, these two files are
recorded in a single other diskette.
The diskettes including the three files 5, 6, and 7 may thereafter
be inputted into the grading computer 8 (FIG. 1) to produce the
graded last files 9 representing the different sizes of lasts for
the respective shoe style, and/or the graded component files 12
representing the different sizes of the components, such as leather
blanks, actually used in manufacturing the shoes for the respective
style.
As one example, the digitizer computer 4 may be the
previously-mentioned Anomatic III CNC computer produced by Anorad
Corporation of Hauppauge, New York. Such computers are well-known
and are commercially available, including technical data enabling
them to be programmed to perform the above operations. Therefore,
further details of the construction and operation of the computer,
and the software for performing the above-described operations, are
not set forth herein.
The Grading Computer 8
Grading computer 8 may be one of the commercially-available
general-purpose personal computers, such as the IBM PC. As shown in
FIG. 1, it includes a keyboard KB.sub.2 and a display DISP.sub.2
for the man-machine interface (MMI) software to control the grading
operations. Since such computers are well-known, further details of
its construction are not set forth herein. FIG. 8 is a flow diagram
illustrating the MMI (man-machine interface) software for the
grading computer 8 of FIG. 1; FIG. 9 is a flow diagram illustrating
the operation of the grading computer; and FIGS. 10a-15b are
diagrams helpful in explaining the grading operation.
With reference first to FIG. 8 illustrating the MMI interface
software involved in controlling the grading operations performed
by computer 8, the operator uses keyboard KB.sub.2 and display
DISP.sub.2 to enter the file name. This includes the same eleven
alphanumeric characters used for designating the file in the
digitizing operations, i.e., the style name (five characters),
grade of last (three characters), and special designations (three
characters).
Next, the operator introduces the pitch required. This may be the
same pitch as entered into the digitizer computer 4 for producing
the model last file, or it may be a different pitch. However,
whereas either a spiral scan or an intermittent scan could be used
in the digitizing operation controlled by the digitizer computer 4
for producing the model last file, when producing the graded last
file in the grading computer the scanning must be a spiral scann to
avoid abrupt changes when cutting the last.
Next introduced into the grading computer 8 is the length of the
model last. This may be the same or different than the one used in
the digitizer computer 4 for producing the model last file. In the
digitizing operation, the longitudinal axis of the last is usually
used as the model length, whereas in the grading operation, the
length of the bottom pattern is usually used as the model
length.
Next introduced are the girth of the model and the bottom width of
the model, both of which are measured according to standard
procedures.
After introducing the above information, the computer asks the
operator "do you want grading?". If the operator (via the keyboard
KB.sub.2) answers "no", the MMI program ends; however, if the
answer is "yes", the operator is then asked "do you want standard
?". If the answer is "yes", the operator is asked to input the
standard required, the size of last required, and the size of
bottom required; the rest of the information is supplied from
standard known data. If, however, a "standard" grading is not
desired, the computer then asks the operator for specific
information concerning the "special" requirements, including the
required size of last, length of last, girth of last, and bottom
width.
This completes the information required for the specific grade
desired, and the operator is then asked "do you want another
grade?". If yes, the program returns to the point in the flow chart
wherein the operator is again asked whether a standard or a special
grade is desired. Whenever another grade is not desired, the
data-inputting phase is completed.
It will thus be seen that the operator can input data for any
desired number of grades desired to be produced, depending upon the
memory capacity of the grading computer 8.
The operation of the grading computer 8 is more particularly shown
in the flow diagram of FIG. 9, taken together with the diagrams of
FIGS. 10a and 10b.
Thus, for each digitized tool path point T in the model last file 5
produced by the digitizer computer 4 (these being the center points
of the tracer probe TP as described above), there is produced a
part contact point P. FIG. 10a illustrates a number of the
tool path points T.sub.1 ---T.sub.n+1, and the corresponding part
contact points P.sub.1 ---P.sub.n. The calculation of the part
contact points P.sub.1 ---P.sub.n is effected in the following
manner.
As shown in FIG. 10b, for each tool-path point T.sub.n, a first
line is connected from T.sub.n to T.sub.n-1, and a second line is
connected from T.sub.n to T.sub.n+1. The angle between the two
lines is then equally divided (.alpha..sub.1 =.alpha..sub.2) by a
line "R" (the tool radius); the end of line "R"determines the part
surface point P.sub.n in the respective two dimensional plane. For
the third dimension, the procedure is repeated along a second
right-angle axis wherein T.sub.n is the apex of a pyramid.
The next operation in the flow diagram illustrated in FIG. 9 is to
detect the data of the feather line FL (FIG. 2). As described
earlier, this data was originally obtained in the digitizing
operation (using computer 4) by making both the tracer probe TP and
the last bottom LB of electrically-conductive material, and the
last size LS of electrically-insulating material, so that the
juncture line between the last bottom and last sides, constituting
the feather line FL, was detected by the conductive tracer probe TP
and recorded in the feather line file 6. The feather line FL data
in file 6 may thus be used in the actual grading operations, as
described more particularly below.
After the grading operation has been performed, the computer then
recalculates the graded tool path points (T), based on the known
dimensions of the tool to be used for cutting the last.
The next operation is to make the required kinematic calculations
to assure that the machine tool controlled by the graded last file
does not exceed predetermined acceleration block process time, and
axis-speed constraints. This is a well-known technique, wherein the
magnitude and direction of the movement of the cutting tool are
resolved into its vector components, and the vector components are
controlled so as not to exceed the predetermined acceleration
constraints. If one of these constraints is exceeded, the computer
program shifts to the next point by interpolation and it then again
makes the kinematic calculations, the process being repeated until
the acceleration constraint is not exceeded, as well-known in such
kinetic calculations.
When the acceleration constraints are not exceeded for the graded
tool path points, the information is stored in a CNC file, e.g., a
diskette or cassette tape, and thereby constitutes one of the
graded last files 9 in FIG. 1, ready for use with a last-cutting
machine 10 or a retrofit machine 11.
The Grading Operation
The grading operation is performed on the data of the part contact
points (P.sub.1 ----P.sub.N) before converting this data to the
tool-path points (T.sub.1 ----TN.sub.N) in the flow diagram of FIG.
9. For each angular position (0), the grading operation converts
the X-axis and the Z-axis coordinates of each sample point on the
model last to the corresponding coordinates on the graded last to
be produced. Briefly, this is done by first determining the grading
coefficients of length, girth, and width, corresponding to the
relationship of these parameters between the model last and the
desired graded last, and then multiplying the sample point
coordinates of the model last by the respective coefficients, as
will be described more particularly below.
However, a straightforward grading in this manner will produce a
proportionate increase or decrease for all the sample points. This
is usually not desirable because it of consumer preference, and
also because this would require separate manufacturing tooling for
each shoe component for each grade. Thus, it is frequently
desirable that a larger size last will not have a heel-height,
toe-spring, and/or toe-thickness increased in the same proportion
as the length and width of the last of another grade. For example,
whereas the shoe length and width may increase in the same
proportion in the larger sizes, the consumer usually prefers a
smaller proportionate increase in the heel height. In addition, it
is frequently desirable that the last bottom have the same
dimension for more than one grade, in order to reduce the tooling
costs that would be involved in producing separate tooling (e.g.,
moulds) for manufacturing a different bottom sole for each shoe
grade.
The described method and apparatus for grading the lasts not only
enable different coefficients to be applied to different portions
of the lasts, (e.g., to increase the resolution at critical
portions such as the back of the heel), but also enable various
"holding" techniques to be applied to adapt the shoe dimensions to
consumer preference and also to minimize tooling costs. FIGS.
11a-11c illustrate a number of such holding techniques.
Thus, FIG. 11a illustrates a model last ML, and also one of a
plurality of graded lasts GL to be produced from the model last.
The "back", "middle" and "front" parts of the graded last are also
indicated. If a straightforward grading operation was performed,
the front part of the graded last would have the "toe-spring" shown
in full lines in FIG. 11a, which would not be desirable.
Accordingly, a "toe-spring" holding technique is applied during the
grading operation to "hold" the toe-spring to that shown in broken
lines. FIGS. 11b and 11c illustrate other holding techniques, e.g.,
"toe-thickness" and "heel-height", that may be applied also to
produce a disproportionate increase (or decrease) in the
toe-thickness and heel-height in the graded lasts.
FIG. 12 is a flow diagram illustrating the grading operation. The
first step is to determine the grading coefficients, KL, KR and
KRB, wherein:
(1) KL is the length coefficient and is equal to the length of the
last after grading (L.sub.G) divided by the length of the model
last before grading (L.sub.M) (i.e., KL=L.sub.G /L.sub.M);
(2) KR is the girth coefficient and is equal to the girth of the
last after grading (G.sub.G) divided by the girth of the model last
before grading (G.sub.M) (i.e., KR=G.sub.G /G.sub.M); and
(3) KRB is the bottom coefficient and is equal to the width of the
last after grading (W.sub.G) divided by the width of the model last
before grading (W.sub.M) (i.e., KRB=W.sub.G /W.sub.M).
These calculations are made from the data manually inputted into
the computer according to the man-machine interface flow (MMI)
diagram illustrated in FIG. 8.
According to the flow chart illustrated in FIG. 12, the computer
then finds each sample point (e.g., 15,000 sample points) of the
digitized model last, and sets a flag for each such sample point
which is on the last bottom. This is easily determinable by the
computer since all the sample points of the last bottom LB are
within the feather line FL of the last, as illustrated in FIG. 2,
and as detected during the digitizing operation and stored in the
feather line file 6 (FIG. 1).
If the sample point is on the last bottom, as indicated by an "on"
flag, the X-coordinate of the sample point is multiplied by the
last bottom grading coefficient KRB, to produce the graded
X-coordinate (Xi) for the respective sample point. On the other
hand, if the sample point is on the last sides, indicated by an
"off" flag, then the X-coordinate of the sample point is multiplied
by the grading girth coefficient KR. In both cases, the
Z-coordinate of the sample point is multiplied by the length
grading coefficient KL.
The grading operation illustrated in the flow diagram of FIG. 12 is
completed when all the sample points (e.g., 15,000) have been thus
graded.
It will be appreciated that if a last bottom of one grade is to be
"held" for another grade, e.g., to minimize tooling costs, then the
parameters of such a last bottom would be entered into the computer
by the operator according to the man- machine interface flow
diagram illustrated in FIG. 8.
It will also be appreciated that any or all of the grading
coefficients KL, KR and KRB may have different values with respect
to the different portions of the shoe last as indicated in FIG.
11a. In this case, the sample points on the different portions of
the shoe last would be flagged, in the same manner as the sample
points on the last bottom are flagged in the flow diagram of FIG.
12, and the respective grading coefficient would be applied to the
sample points.
FIG. 13 is a diagram illustrating how a "heel-height" holding
technique may be applied to the graded last so as to produce a
disproportionate change in heel height as illustrated by the broken
lines in FIG. 11c; FIG. 14 is a flow diagram illustrating the
manner of implementing the heel-height holding technique; and FIGS.
15a and 15b are diagrams illustrating the computations made by the
computer when implementing this technique.
With reference first to the flow diagram of FIG. 14, the graded
last produced by the above-described grading operation, before
applying the "heel-holding" procedure, is displayed in display
DISP.sub.2 (FIG. 1), therein appearing in the form of the full
lines of FIG. 13. The operator then selects a pivot point "P" on
the turning center line TCL, and a point "O" on the heel part of
the last; and, by manipulating the controls of the display, pivots
the displayed graded last about pivot point P to the desired heel
height. The thus-pivotted last is indicated by the broken-lines in
FIG. 13. It will thus be seen that the graded heel height before
pivotting is indicated at H.sub.G, and the "hold" heel height is
indicated at H.sub.H.
The computer measures the angle (.alpha.) between the original line
TCL and the pivotted line TCL, and also measures the dimension "l"
between the original point "O", and the corresponding point "O"
after pivotting. The computer then convert each of the sample
points "a" before pivotting to the corresponding values "a" after
pivotting, in the following manner as illustrated in FIGS. 15a and
15b.
FIG. 15a illustrates the slice along plane AA of FIG. 13; the
graded model last is shown in full lines before "correction", and
in broken lines after correction. Point "a" in FIG. 15a is any one
of the (e.g., 15,000) sample points on the outer contour of the
graded last before correction; the sample point is defined by the
distance "X" along the X-axis, and the angle .theta. about the
turning center line TCL. Point "a" represents the corresponding
point on the contour after correction, this point being fixed by
determining the corresponding parameter "X" and ".theta." after
correction.
The diagram of FIG. 15b illustrates how "X" and "O" are determined,
using the following equations and the measured value "l", namely
the distance between "O" and "O" in the slice AA: ##EQU1##
The foregoing calculation is made for fixing each of the sample
points "a" on the contour of the graded last in the plane AA.
After the values of "a" have been determined in the plane AA, the
corresponding values are determined for all the other planes
through the graded last. This is done by changing the value "l"
while maintaining the same angle ".alpha.".
FIGS. 13, 14, 15 and 15b thus illustrate the manner of converting
the sample points for applying a "heel" holding technique to the
graded last. It will be appreciated that basically the same
procedure may be followed when applying a "toe-spring" or
"toe-thickness" holding technique to the graded last. It will also
be appreciated that instead of pivotting the graded last about one
pivot point "P", the graded last may be pivotted about two or more
pivot points to implement the desired holding in a more precise
manner.
Producing Graded Shoe Components
and apparatus may also be used for grading the components utilized
in manufacturing the shoes. As indicated earlier, for this purpose
style-lines SL are marked on the model last ML (FIGS. 2 and 16a) to
indicate the stitching edges of the components, and the digitizer 4
(FIG. 1) produces not only a model last file 5 representing the
outer contour of the last, but also a style-line file 7
representing the location of the style-lines SL.
The foregoing operations are also illustrated in the flow diagram
of FIG. 16b, wherein it will be seen that the operation of
digitizing the model last produces a model last file, e.g.,
carrying the file name "A1234 B08 DGT", and a style-line file,
carrying the corresponding file name "A1234 B08 ANS", but in the
style-line file 7.
Both files 5 and 7 are then subjected to the same grading operation
as described above with respect to FIGS. 8-15b under the control of
the man-machine interface MMI, which specifies the particular
parameters of the desired grade as also described above.
As shown in FIG. 16, the grading operation produces a first series
of files for the desired grade, in CNC (computerized numerical
control) format, and a corresponding series of graded sensor files,
namely, the graded files produced from the sensor file which
combined the digitized data in the feather line file 6 and the
style-line file 7.
The graded sensor files are then used for defining the components
of the shoe represented by the graded lasts. This is done under the
control of the
hine interface MMI using keyboard KB.sub.2 and display DISP.sub.2
(FIG. 1), wherein the operator displays the graded last with the
graded style-lines thereon, applies a name to each style-line, and
then defines the respective components by three or more such
style-lines. For example, component C.sub.1 in FIG. 16a would be
defined by lines SL2, SL3 and SL4.
The output of this operation is a series of files for each
component, each file in the series representing a different grade
of the corresponding component. This is illustrated in the flow
diagram of FIG. 16b by a first file series representing the
different grades of one component, a second file series
representing the different grades of a second component, and so on
with respect to all the components of the shoe to be graded.
The latter files represent the three-dimensional configuration of
the graded components. These files are then converted to
two-dimensional configurations by known algorithms, thereby
producing graded digital files representing the two-dimensional
configurations of the components used for manufacturing the shoe.
The so-produced files, corresponding to the graded component files
12 in FIG. 1, may thus be used in conventional CNC (computerized
numerical control) machines for manufacturing the components.
Laser Digitizer
Instead of using a tracer-point type digitizer as illustrated in
FIG. 3, there may also be used an optical-type digitizer. FIG. 17
illustrates a laser digitizer which may be used for this purpose,
and PG,44 FIG. 18 illustrates the flow diagram when using this type
of digitizer.
The laser digitizer illustrated in FIG. 17 also includes a rotary
motor M.sub..theta. for rotating the model last ML about its
turning center line TCL, an encoder E.sub.O producing an electrical
output representing the instantaneous ngular position (.theta.) of
the model last about line TCL; a motor M.sub.Z for driving the
laser probe LP along the Z-axis, parallel to line TCL; and an
encoder E.sub.Z producing an electrical output representing the
instantaneous linear position of the laser probe LP along the
Z-axis. The laser digitizer of FIG. 17, however, does not include
any means for displacing the laser probe LP about the X-axis,
perpendicular to line TCL, nor a corresponding encoder; rather, the
laser probe LP itself determines the X-coordinate of the sample
point on the surface contour of the model last ML.
Laser probes of this type are known, and therefore particulars of
the construction and operation of the laser probe LP are not set
forth herein. As one example, the laser probe LP may be the OP2
Laser Scanning Probe distributed by Renishaw, widely used for
non-contact measurement of a wide range of components.
It will be appreciated that, whereas the tracer probe TP of FIG. 3
outputs the X-dimension of the sampled points in the form of
tool-path points (points T, FIG. 10a, namely the center point of
the tracer wheel), the X-axis coordinate outputs of the laser probe
LP in FIG. 17 represent the actual part points (points P, FIG. 10a)
on the outer surface of the model last ML being digitized. Thus,
the information appearing in the Model Last File 5 outputted by the
digitizer computer would be the part points P when the laser probe
is used. Accordingly, when the file produced by the laser probe of
FIG. 17 is used in the grading computer 4 to produce the graded
last files for use in the CNC cutting machine, it is not necessary
to convert the tool path points (points T) to the part contact
points (points P) before performing the grading operations, as
described above with respect to the flow diagram of FIG. 9; rather,
this step is omitted when using the laser probe LP.
FIG. 18 is a flow diagram, corresponding to that of FIG. 9,
illustrating the operation of the grading computer 8 when the model
last file 5 is produced by the laser probe LP digitizer of FIG. 17.
Thus, each sample point in the model last file is the part contact
point (P), instead of the tool-path point (T) in FIG. 9. The part
contact points (P) are then graded for lengths and widths in the
same manner as described above, and then the tool path points (T)
are calculated according to the dimensions of the tool to be used
in cutting the last. The kinematic calculations are then made as
described above with respect to FIG. 9 to assure that the
acceleration and other constraints are not exceeded, before the
tool path points are recorded in the produced CNC file.
Applications of the Invention
As indicated above, the described method and apparatus may be
embodied in new equipment specifically designed for making shoe
lasts or for making the graded components used in manufacturing the
shoes. The invention may also be embodied in existing equipment,
e.g., of the pantographic type, to retrofit such equipment for
making graded shoe lasts. Further, the invention may also be used
in CAD/CAM (computer-aided design/computer-aided manufacture)
equipment, for changing styles or creating new styles, by enabling
the style-designing artisan to display on the screen the image of
the model last from the digital data generated by the digitizer
computer, and then to manipulate the displayed image, according to
the above-described "holding" techniques or other known graphic
manipulating techniques, to modify the displayed style or to create
new styles.
Many other variations, modifications and applications of the
invention may be made.
* * * * *